Shoe

ABSTRACT

The present invention relates to methods and devices for forming an upper of a piece of footwear, wherein the method comprises the steps of forming a first shaped piece and a second shaped piece of the footwear upper and laminating the two shaped pieces together. The present invention further relates to a method of printing on the surface of a piece of a shoe while the piece is in a substantially planar configuration, and then shaping the piece. The piece may then subsequently be used in the method of forming a piece of footwear.

TECHNICAL FIELD

The present invention relates generally to footwear, and more particularly to a method for forming a piece of a footwear upper.

BACKGROUND OF THE INVENTION

Sports and casual footwear is typically constructed from a number of pieces, each of the pieces typically comprising a number of layers. The pieces forming the footwear upper are typically stitched at their edges to bond the layers together. Whilst this method leads to a sturdy construction, the presence of seams within an article of footwear is undesirable and can lead to irritation and discomfort for the wearer, particularly at or near edges which may rub against the wearer during use. Further, seams may degrade the aesthetic appearance of the footwear.

Accordingly, there is a continued effort by footwear manufacturers to develop methods of providing footwear rapidly and at a reduced cost, whilst maintaining rigidity and structural integrity. There is also a further need for the manufacturers to improve their ability to position identifying features, marks, brands and patterns onto the surface of the footwear, and in particular the upper of the footwear, without interfering with the speed and efficiency of construction. The present invention aims to address these and other issues.

SUMMARY OF THE INVENTION

In a first aspect, the present invention relates to a method of forming an upper of a shoe, the method comprising the steps of forming a first shaped piece of the shoe upper; forming a second shaped piece of the shoe upper and laminating the first shaped piece of the shoe upper to the second shaped piece of the shoe upper. In alternative embodiments, an upper may be formed of further shaped pieces which are laminated to one of more of the other constituent shaped pieces. The lamination may improve the structural rigidity and durability of one or more of the pieces.

By “shaped piece” is meant a piece which is in a substantially non-planar configuration.

In an embodiment of the method, the laminating of at least one of the first shaped piece and second shaped piece may occur during one or more steps of molding. If further shaped pieces are used, these may also be laminated to at least one other of the pieces during one or more steps of molding. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as lubricating fluid) to facilitate easier molding.

The method of forming of at least one of the first shaped piece and the second shaped piece may comprise one or more steps of molding, or one or more steps of laminating or any combination thereof. If further shaped pieces are used, these may also be formed via steps which comprise one or more molding steps, one or more laminating steps, or a combination thereof.

The method of forming at least one of the first shaped piece and the second shaped piece may comprise the step of trimming one or more of the shaped pieces from one or more larger pieces. If further shaped pieces are used, these may also undergo a step where one or more are trimmed from a larger piece. Two or more shaped pieces may further be trimmed from the same larger piece. If two or more shaped pieces are trimmed from the same larger piece, it may be that there is no wastage of material. For example the second shaped piece may comprise the remainder resulting from trimming the first shaped piece.

In a further embodiment, at least one of the first shaped piece and the second shaped piece may comprise two or more components. The method may comprise the step of joining at least one component to at least one other component by one or more of stitching, ultrasonic welding, adhesive means or heat treatment, but alternative joining mechanisms will be suitable.

One or more of the first shaped piece and the second shaped piece may comprise two or more components which have undergone a step of laminating. This laminating may occur during one or more molding steps.

One or more of the components may comprise a portion which has been previously shaped, for example mechanically or by molding. One or more of the components may itself comprise a laminated component. The components (which may or may not be laminated) may comprise one or more of fabric or foam.

By the term “laminated component” is meant a component comprising one or more layers which are joined together. The join may be temporary or permanent, and may be frangible. The join may comprise any suitable joining mechanism, for example one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment. The term does not relate to the extent of the one or more layers, which may partially overlap, fully overlap or in the case of more than two layers, may not overlap at all. A laminated component may or may not be at least partially covered by a layer of adhesive.

In a further embodiment, one or more of the first shaped piece and the second shaped piece may comprise one or more cushioning components. The cushioning components may or may not be placed at certain anatomical locations to increase cushioning, for example at the heel. The cushioning components may comprise foam, but alternative materials would be suitable. Furthermore if multiple cushioning components are provided, they need not comprise the same material, shape or be directed to the same purpose. The cushioning components may alternatively comprise a sealed region of fluid, or an alternative resilient means to cushion the user's foot. The method may comprise the step of positioning the cushioning components between one or more overlaying portions of one or more other components. Alternatively, the cushioning components may be positioned such that, after one shaped piece and a further shaped piece are laminated together, the cushioning component sits between two or more overlapping portions of the shaped pieces, or components thereof.

In another embodiment, at least one of the overlaying components further comprises a portion which does not overlay at least one other component. The method may comprise a step of ‘hemming’ the portion that does not overlay at least one other component.

In a further embodiment of the method, at least a portion of the first shaped piece and the second shaped piece may be adapted to overlay the other of the first shaped piece and the second shaped piece. If further pieces are being used, these may comprise portions which are partially adapted to overlay one or more other pieces. One or more pieces may further comprise a portion which does not overlay at least one other piece. The method may comprise a step of ‘hemming’ the portion that does not overlay at least one other piece.

By “hemming” is meant the process of folding the one or more non-overlapping portions of a component/piece over the edge of one or more components/one or more pieces (which may be the same component/piece) and attaching, for example by stitching, the folded part to the remainder of the one or more components/one or more pieces.

The method may include the step of joining the first shaped piece to the second shaped piece. The first shaped piece and the second shaped piece may be joined, before, after or during the laminating step. The joining may be performed by one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment. However, other methods of joining will be suitable, and may depend on the materials to be joined and the speed with which the join must be formed. The join may comprise an additional piece or pieces, for example the join could be a hook and loop fastener (for example, Velcro) or a shoelace.

In a further embodiment, the method comprises the step of inverting the configuration of the pieces such that the outermost piece of the first shaped piece and second shaped piece becomes the innermost piece of the first shaped piece and second shaped piece. If more than two pieces are used in the upper, the configuration of at least two of the pieces may be inverted this way. For example, if the upper comprises three pieces, the original innermost piece may become the outermost piece; the original outermost piece may become the innermost piece while the middle piece may remain the middle piece. Alternative inversions of the configuration of two or more of the pieces are also possible. This inversion may improve the ease with which the upper can be assembled as, for example, joins may be more easily accessed. Inversion may also move seams inwards, for example, improving the aesthetic appearance of the outer of the upper, or may alternatively or additionally move seams outwards to reduce, for example, rubbing against a user's foot.

In still a further embodiment of the present invention, at least a portion of one or more of the pieces forms an aperture having a rim in the upper. The aperture may be formed in only a single piece, or may be collectively formed by two or more pieces. The rim of the aperture may further comprise a strip which at least partially covers the rim of the aperture. The strip may be attached by one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment; however other methods of attachment will be suitable.

The method of making the upper of the shoe may further comprise the step of attaching one or more sole components to the shoe upper. The sole components may be one or more midsoles or one or more outersoles. The sole components may be attached by one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment; however other methods of attachment will be suitable. The sole components may comprise one or more of foam, fabric, plastic or leather. The sole components may have a non-uniform thickness and may comprise their own cushioning components in addition or instead of the cushioning components of the upper. One or more sole components may partially or wholly overlap the upper of the shoe.

There is further provided a method for making a shoe, comprising the steps of forming the upper according to any of the above methods.

In a second aspect, the present invention provides an upper of a shoe made according to one or more of the previous methods. The upper of the shoe comprises a first shaped piece; a second shaped piece; wherein at least a portion of the first shaped piece and the second shaped piece are laminated together. Additional shaped pieces may further be used and may be laminated to one or more of the other shaped pieces.

At least one of the shaped pieces may comprise a molded piece, a laminated piece or a piece trimmed from a larger piece. Two or more the shaped pieces may further be trimmed from the same larger piece. If two or more shaped pieces are trimmed from the same larger piece, it may be that there is no wastage of material. For example the second shaped piece may comprise the remainder resulting from trimming the first shaped piece.

One or more of the shaped pieces may comprise a plurality of components. These components may be joined together by one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment; however other methods of attachment will be suitable.

One or more of the shaped pieces may alternatively or additionally comprise a plurality of laminated components.

The plurality of components (which may or may not be laminated) may have been shaped previously, for example by molding. Further, one of more of the components themselves may be laminated, and may comprise one or more of fabric, foam, leather or plastic. One or more of the components may comprise a portion at least partially adapted to overlay one or more other of the components.

In a further embodiment, one or more of the first shaped piece and the second shaped piece may comprise one or more cushioning components. The cushioning components may or may not be placed at certain anatomical locations to increase cushioning, for example at the heel. The cushioning components may comprise foam, but alternative materials would be suitable. Furthermore, if multiple cushioning components are provided, they need not comprise the same material, shape or be directed to the same purpose. The cushioning components may alternatively comprise a sealed region of fluid, or an alternative resilient means to cushion the user's foot. The cushioning components may be positioned between one or more overlaying portions of one or more other components. Alternatively, the cushioning components may be positioned such that, after first shaped piece and second shaped piece are laminated together, the cushioning component sits between two or more overlapping portions of the first shaped piece and the second shaped piece, or components thereof.

In another embodiment, at least one of the overlaying components further comprises a portion which does not overlay at least one other component. This portion may be ‘hemmed’ to a further portion of the component or to another component.

In yet a further embodiment of the upper, at least a portion of the first shaped piece and the second shaped piece may be adapted to overlay the other of the first shaped piece and the second shaped piece. If further pieces are being used, these pieces may comprise portions which are partially adapted to overlay one or more other pieces. One or more pieces may further comprise a portion which does not overlay at least one other piece. One or more pieces may be ‘hemmed’ to themselves or to one or more other pieces.

One or more pieces of the upper may be joined before, during or after lamination. The join may comprise one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment; however other means of joining will be suitable.

In still a further embodiment of the present invention, at least a portion of one or more of the pieces forms an aperture having a rim in the upper. The aperture may be formed in only a single piece, or may be collectively formed by two or more pieces. The rim of the aperture may further comprise a strip which at least partially covers the rim of the aperture. The strip may be attached by one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment; however other methods of attachment will be suitable.

The upper of the shoe may further comprise one or more sole components. The sole components may be one or more midsoles or one or more outersoles. The sole components may be attached by one or more of stitching, adhesive means, welding (including ultrasonic welding) or heat treatment; however other methods of attachment will be suitable. The sole components may comprise one or more of foam, fabric, plastic or leather. The sole components may have a non-uniform thickness and may comprise their own cushioning components in addition or instead of the cushioning components of the upper.

There is further provided a shoe which may comprise the upper of any of the above embodiments.

In a third aspect of the present invention, there is provided a method of forming a decorative pattern on a portion of an upper of a shoe, the method comprising the steps of printing a decorative pattern on at least a portion of a shoe upper, the portion of the shoe upper having a substantially planar configuration and shaping the portion of the shoe upper to form a predetermined shape. One advantage of this method is that printing onto a 2D surface is less complex than printing onto a 3D surface, thus according to the method of the present invention there is provided a means of printing onto a 3D object while it is in a substantially 2D configuration. This may for example, reduce distortions, improve the printing quality and prevent unwanted accumulations of ink in recesses of the 3D object.

By “portion of an upper of a shoe” is meant the surface of the upper of a shoe; this may be a portion of the surface of the upper while it has a substantially planar configuration, but may further refer to the entirety of the upper of the shoe while it is in a substantially planar configuration.

In an embodiment of the present invention, a portion of the shoe upper may comprise a laminated portion. In a further embodiment, the shaping of the portion of the shoe upper to form a predetermined shape may comprise a molding step. Other methods of shaping may be employed, for example mechanical shaping. The portion of the shoe upper may comprise one or more of fabric, foam, plastic or leather.

The printing may comprise one or more steps of screen printing.

By “screen printing” is meant the known method of printing a design onto clothing items, for example T-shirts.

The printing may comprise printing onto a plurality of substantially planar portions of the shoe upper. The printing may occur on one portion separately from the printing on any other portion, or the printing may occur sequentially onto the same portion to ‘build-up’ a design.

The methods of this aspect may be combined with the methods of the first aspect, wherein the third aspect comprises one or more steps in the formation of one or more of the shaped pieces or components to be used in the method of the first aspect.

In a fourth aspect, there is provided a decorated portion of an upper of a shoe comprising one or more layers of substantially planar material and a decorative image, wherein the decorative image is printed on at least part of a surface of a portion of the shoe upper whilst the portion of the shoe upper is in a substantially planar configuration, and wherein the portion of the shoe upper is subsequently shaped into a predetermined shape.

The portion of the upper of a shoe may comprise at least a partially laminated portion, and may comprise one or more of fabric, foam, plastic or leather.

The decorated portion may comprise at least one screen printed decorative image.

The decorated portion of the fourth aspect may comprise part or all of a component or piece of the upper of a shoe according to the second aspect of the present invention.

BRIEF DESCRIPTION OF THE FIGURES

These and other features and advantages of the present invention will be better understood by reference to the following detailed description of specific embodiments of the present invention and the accompanying drawings. It is understood that the embodiments shown in the drawings are intended for illustrative purposes and are not to be considered limiting on the present invention. In the drawings:

FIGS. 1A-1H are a series of perspective views and side elevations of the stages of an embodiment of a method of forming the first shaped piece and the second shaped piece for an upper of a shoe.

FIGS. 2A-2D are a series of perspective views and side elevations of an embodiment of a method of joining the first shaped piece and the second shaped piece to form the upper of a shoe including the step of laminating the first shaped piece to the second shaped piece.

FIGS. 3A-3D are a series of perspective views and side elevations of a different embodiment of a method of joining the first shaped piece and the second shaped piece to form the upper of a shoe including the step of laminating the first shaped piece to the second shaped piece.

FIGS. 4A-4D are a series of perspective views and side elevations of a further embodiment of a method of joining the first shaped piece and the second shaped piece to form the upper of a shoe including the step of laminating the first shaped piece to the second shaped piece.

FIGS. 5A-5D are a series of perspective views and side elevations of a yet another embodiment of a method of joining the first shaped piece and the second shaped piece to form the upper of a shoe including the step of laminating the first shaped piece to the second shaped piece.

FIGS. 6A-6D are a series of perspective views of an embodiment of a method of printing a decorative design onto a piece of material which may form a component or piece of an upper of a shoe.

DETAILED DESCRIPTION OF THE INVENTION

In the following, the phrase “convex mold” refers to the portion of the mold which contains a protrusion designed to complement a recess in the complementary concave mold. This term does not describe the shape of the protrusion in any way.

In the following, the phrase “concave mold” refers to the portion of the mold which contains a recess designed to be complementary to and substantially accommodate the protrusion of the convex mold. This term does not describe the shape of the recess in any way.

The molding steps described herein may be performed in a single pair of concave and convex molds, or in one or more pairs of concave and convex molds as is needed.

FIG. 1A shows an embodiment of the steps of producing a laminated first component of a shoe upper before it has been shaped. Laminated component 10 is formed from the combination of layers of foam 12, adhesive 14 and fabric 16. The figure shows two layers of material (foam 12 and fabric 16) joined by an adhesive, but this is not intended to be limiting and laminated component 10 may comprise only a single layer (which may therefore not be laminated), or may comprise more than two layers. The two material layers are shown joined by adhesive layer 14, but alternatively the two or more material layers may be joined by other non-adhesive means for example by ultrasonic welding or heat treatment. Furthermore, the two layers 12, 16 are shown completely overlapping; however it is not necessary for the two layers to completely overlap and the two layers may only partially overlap. If multiple layers are present, each layer may completely overlap some or all of the other layers, may only partially overlap some or all of the other layers, or may not overlap some other layers. Furthermore the layers 12, 16 may have a substantially planar configuration when they are laminated, but this is not required and alternative configurations are also suitable. Furthermore, adhesive layer 14 need not cover the entirety of the gap between the material layers 12, 16, but may do so. In addition, it is not required that the materials comprise fabric and foam and one or more alternative materials may be suitable.

FIG. 1B shows the shaping of laminated component 10 by molding. It will be recognised that the shaping could be performed by other means and shaping by molding is not a limitation of this method. Convex mold 20 and concave mold 18 are substantially adapted to complement each other. Laminated component 10 is positioned between convex mold 20 and concave mold 18, the portions of the mold are pressed together and the laminated component 10 is shaped into a 3D configuration. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as a lubricant) to one or more of the laminated component 10, convex mold 20 and concave mold 18 to facilitate easier molding.

FIG. 1C shows the application of a further layer of adhesive 22 to the laminated component 10 in the 3D configuration. Applying this adhesive may aid later lamination. It will be understood that this step is optional. Furthermore, the adhesive layer 22 does not need to be applied to the whole surface of laminated component 10, but may be. The adhesive layer is also shown applied to foam layer 12 of laminated component 10, but adhesive could be applied to another layer or to more than one layer of laminated component 10.

FIG. 1D shows laminated component 10 in a 3D configuration and laminated component 24 in a substantially planar configuration. Laminated component 24 is formed from the combination of layers of foam 28 and adhesive 26. The figure shows one layer of material covered by an adhesive, but this is not intended to be limiting and laminated component 24 may comprise more than one layer. The foam layer 28 is shown covered by an adhesive layer 26, but alternatively two or more material layers may be present and may be joined by further adhesive layers. The joins between layers may by other non-adhesive means for example by ultrasonic welding or heat treatment. If multiple layers are present, each layer may completely overlap some or all of the other layers, may only partially overlap some or all of the other layers, or may not overlap some other layers at all. Furthermore, adhesive layer 26 need not cover the entirety of material layer 28 but may do so. In addition, it is not required that the material comprises foam and one or more alternative materials may be suitable. Laminated component 24 is shown in a substantially planar configuration, but this is not required, and laminated component 24 may have undergone shaping (for example by molding) prior to, during or after lamination, and prior to, during or after applying adhesive. The substantially planar configuration is exemplary only. Positioned between laminated component 24 and laminated component 10 are shown cushioning components 30 at positions in the heel and toe of the upper. The locations are not limiting and cushioning could be provided in other anatomical locations, or not at all. Furthermore, the cushioning components 30 could themselves comprise multiple substituent cushioning components. Cushioning components may comprise foam as in this embodiment, but other cushioning mechanisms or materials may be suitable.

FIG. 1E shows the components 10, 24, 30 of FIG. 1D being shaped in a mold. The shaping of these components does not need to take place in a mold, and alternative shaping may be possible. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as a lubricant) to one or more of the laminated components 10, 24, convex mold 34 and concave mold 32 to facilitate easier molding. Laminated component 10 is positioned between convex mold 34 and laminated component 24. Laminated component 24 is positioned between laminated component 10 and concave mold 32. This positioning is not limiting and in an alternative embodiment laminated component 10 may be positioned between concave mold 32 and laminated component 24. Laminated component 24 may be positioned between laminated component 10 and convex mold 34. Further laminated components may also be included. As is shown in the Figure, laminated component 10 is already in a 3D configuration and laminated component 24 is in a substantially planar configuration. These configurations are not limiting and both components could be in 3D configurations. If further laminated components are also introduced, then these may be in substantially planar or in 3D configurations. In addition, the laminated components 10, 24 are shown completely overlapping. This is also not limiting and the laminated components may only partially overlap in the mold. If further laminated components are present, each laminated component may completely overlap some or all of the other laminated components, may only partially overlap some or all of the other laminated components, or may not overlap some other laminated components at all. The inset of FIG. 1E shows the positioning of the laminated components 10, 24 in the exemplary embodiment, and the constituent layers 12, 16, 28 of each laminated component 10, 24 and the cushioning 30 while in the mold 32, 34. The composite of laminated components 10, 24 and cushioning components 30 will be referred to as the “laminated composite” hereafter.

FIG. 1F shows the laminated composite of shaped laminated components 10, 24 and cushioning components 30 in a 3D configuration. An adhesive layer 36 is added to a surface of the composite and may aid later lamination. As with the step shown in FIG. 10, it will be understood that this step is optional. Furthermore, the adhesive layer 26 does not need to be applied to the whole surface of the laminated composite, but may be. The adhesive layer is also shown applied to foam layer of laminated component 24, but adhesive could be applied to another laminated component 10 or to more than one laminated component in the laminated composite.

FIG. 1G shows the shaping of component 38 by molding. It will be recognised that the shaping could be performed by other means and shaping by molding is not a limitation of this method. Convex mold 42 and concave mold 40 are substantially adapted to complement each other. Component 38 is positioned between convex mold 42 and concave mold 40, the portions of the mold are pressed together and the laminated component 38 is shaped into a 3D configuration. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as a lubricant) to one or more of the component 38, convex mold 42 and concave mold 40 to facilitate easier molding. It should be understood that component 38 is shown as comprising a single layer. This is not a limitation of the method and the component 38 could be a laminated component comprising multiple layers, as described previously in relation to laminated components 10 and 24. This component may further comprise cushioning components. If component 38 is a laminated component, the constituent layers may be joined together, for example by adhesive or by ultrasonic welding. Component 38 may comprise one or more of fabric, foam, plastic and leather. Component 38 may further comprise a laminated composite similar to that described in relation to FIGS. 1E and 1F.

FIG. 1H shows the laminated composite comprising components 10, 24, 30 and the separately formed component 38 being trimmed 44. The trimming of the laminated composite and component 38 creates an aperture with a rim into which a foot or similar extremity can pass through or be pushed through. The laminated composite and component 38 are further trimmed to remove excess material. It will be understood that the steps of trimming are optional; the aperture with a rim could be molded or substantially molded during the fabrication of one or more of the laminated composite and the component 38. Alternatively, there may not be any excess material to remove by trimming. Trimming 44 could be performed by scissors as shown, but could also be performed by any suitable means, such as by a laser, or by forming one or more components of the laminated composite and component 38 with a frangible connection between the part to be kept and the excess material to be discarded, and this frangible connection may be broken. After optional trimming, the component 38 forms the first shaped piece 50 of an upper of a shoe, the laminated composite comprising the laminated components 10, 24 and cushioning component 30 forms the second shaped piece 52 of the upper of a shoe. Both first shaped piece 50 and second shaped piece 52 may comprise further components, which may or may not be laminated. Additional shaped pieces may also be provided to form a complete upper of a shoe.

FIG. 2A shows the step of combining first shaped piece 50 and second shaped piece 52. In the present embodiment of the method of the invention, the two shaped pieces 50, 52 are stacked and are joined by stitching. It will be recognised that the two shaped pieces 50, 52 need not be joined by stitching, and could be joined by other means for example heat treatment. Alternatively, a combination of joining methods may be employed. The join may be around the entire length of the contacting parts of the two pieces (such as in the case of the stitching in the present embodiment), or may be around only a portion of the contacting parts. The stacking and/or joining may result in the first shaped piece 50 and second shaped piece 52 partially overlapping, substantially overlapping or completely overlapping as in the present embodiment. The composite of first shaped piece 50 and second shaped piece 52 is then ‘folded right side out’. By this is meant the process whereby the configuration of the first shaped piece 50, originally on the inside of the upper of the shoe and the second shaped piece 52, originally on the outside of the upper of the shoe is altered so that the first shaped piece 50 is positioned on the outside of the upper of the shoe and the second shaped piece 52 is positioned on the inside of the upper of the shoe. This process may be completed by moving first shaped piece 50 in the direction of arrow A1. Stacking and joining the shaped pieces 50, 52 the ‘wrong way round’ may make the process of joining easier to perform and may mean that a join appears on the inside of the upper of the shoe after folding, improving the aesthetic appearance of the upper. It will be recognised that this step of joining the ‘wrong way round’ and ‘folding right side out’ is optional.

FIG. 2B shows the configuration of the composite of the first shaped piece 50 and second shaped piece 52 after they have been ‘folded right side out’. The inset shows the constituent material layers 12, 16, 28 which comprise the laminated components 10, 24, cushioning components 30 and component 38 which form part of the shaped pieces 50, 52 of the upper of the shoe. Stitches 54 on the inside of the upper are also shown which may help to hold the composite of first shaped piece and second shaped piece together.

FIG. 2C shows the method of laminating the first shaped piece 50 and the second shaped piece 52 together. The shaped pieces 50, 52 form a composite (in this case joined together by stitching) which then undergoes a further laminating process. In the present embodiment, the laminating process takes place in a mold comprised of convex mold 58 and concave mold 56. Convex mold 58 and concave mold 56 are substantially adapted to complement each other. The composite of shaped pieces 50, 52 is positioned between convex mold 58 and concave mold 56, the portions of the mold are pressed together and the composite of pieces 50, 52 is laminated. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as a lubricant) to one or more of the composite 50, 52, convex mold 58 and concave mold 56 to facilitate easier molding. It will be understood that a further piece or pieces of the upper could be inserted at this stage and further laminated to one or more other pieces of the upper. Such piece or pieces may be positioned between the composite of first and second shaped pieces 50, 52 and one or more of the convex mold 58 or concave mold 56 prior to laminating. It will be understood that the lamination need not take place in a mold. The lamination may further comprise the step of applying adhesive to one or more shaped pieces of the upper of the shoe to join one shaped piece to another of the one or more shaped pieces. The lamination may still further comprise the step of reshaping the laminated composite of first shaped piece 50 and second shaped piece 52, before, during or after the lamination.

FIG. 2D shows the method of attaching a midsole 60 and an outsole 66 to the laminated composite 50, 52. In the present embodiment, the midsole 60 is attached by stitching 62 and covers the whole of the base of the upper. In alternative embodiments, the midsole may be attached by other means, such as by ultrasonic welding. In alternative embodiments, the midsole is omitted, or only covers a portion of the base of the upper. Further the midsole may comprise one or more components and need not be a singular piece as shown in the Figure. The midsole or midsole components may additionally extend over the edges of the laminated composite to increase the contact area for attachment. The midsole 60 may further have a non-uniform thickness. In the present embodiment, the outsole 66 is attached by adhesive means 64 to the base of the midsole 60. The attachment may be performed by other means, such as by welding. The outsole 66 may be attached to the both the midsole 60 and the laminated composite 50, 52, or just to the laminated composite 50, 52. Additionally, the outsole 66 may comprise one or more components and need not be the singular piece as shown in the Figure. The outsole 66 or outsole components may additionally extend over the edges of the laminated composite 50, 52 to increase the contact area for attachment. The outsole 66 may also have a non-uniform thickness.

FIG. 3A shows the step of combining first shaped piece 50 and second shaped piece 52. In an alternative embodiment of the method of the present invention, the two shaped pieces 50, 52 are stacked and are joined by ultrasonic welding. It will be recognised that the two shaped pieces 50, 52 need not be joined by ultrasonic welding, and could be joined by other means for example heat treatment. Alternatively, a combination of joining methods may be employed. The join may be around the entire length of the contacting parts of the two pieces (such as in the case of the ultrasonic welding in the present embodiment), or may be around only a portion of the contacting parts. The stacking and/or joining may result in the first shaped piece 50 and second shaped piece 52 partially overlapping, substantially overlapping or completely overlapping as in the present embodiment. The composite of first shaped piece 50 and second shaped piece 52 is then ‘folded right side out’. By this is meant the process whereby the configuration of the first shaped piece 50, originally on the inside of the upper of the shoe and the second shaped piece 52, originally on the outside of the upper of the shoe are is altered so that the first shaped piece 50 is positioned on the outside of the upper of the shoe and the second shaped piece 52 is positioned on the inside of the upper of the shoe. This process may be completed by moving first shaped piece 50 in the direction of arrow A1. Stacking and joining the shaped pieces 50, 52 the ‘wrong way round’ may make the process of joining easier to perform and may mean that a join appears on the inside of the upper of the shoe after folding, improving the aesthetic appearance of the upper. It will be recognised that this step of joining the ‘wrong way round’ and ‘folding right side out’ is optional.

FIG. 3B shows a detail of the ultrasonic welding of FIG. 3A, whereby the configuration of the first shaped piece 50 and second shaped piece 52 is altered to position the components ‘folded right side out’. The weld line 51 joins the first shaped piece 50 to the second shaped piece 52 and subsequently the folding takes place as shown by arrows A2 and A3. Ultrasonic welding may help to hold the composite of first shaped piece 50 and second shaped piece 52 together.

FIG. 3C shows the method of laminating the first shaped piece 50 and the second shaped piece 52 together. The shaped pieces 50, 52 form a composite (in this case joined together by ultrasonic welding) which then undergoes a further laminating process. In the present embodiment, the laminating process takes place in a mold comprised of convex mold 58 and concave mold 56. Convex mold 58 and concave mold 56 are substantially adapted to complement each other. The composite of shaped pieces 50, 52 is positioned between convex mold 58 and concave mold 56, the portions of the mold are pressed together and the composite of pieces 50, 52 is laminated. The inset shows the constituent material layers 12, 16, 28 which comprised the laminated components 10, 24, cushioning components 30 and component 38 which form part of the shaped pieces 50, 52 of the upper of the shoe. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as a lubricant) to one or more of the composite 50, 52, convex mold 58 and concave mold 56 to facilitate easier molding. It will be understood that a further piece or pieces of the upper could be inserted at this stage and further laminated to one or more other pieces of the upper. Such piece or pieces may be positioned between the composite of first and second shaped pieces 50, 52 and one or more of the convex mold 58 or concave mold 56 prior to laminating. It will be understood that the lamination need not take place in a mold. The lamination may further comprise the step of applying adhesive to one or more shaped pieces of the upper of the shoe to join one shaped piece to another of the one or more shaped pieces. The lamination may further comprise the step of reshaping the laminated composite of first shaped piece 50 and second shaped piece 52, before, during or after the lamination.

FIG. 3D shows the method of attaching a midsole 60 and an outsole 66 to the laminated composite 50, 52. In the present embodiment, the midsole 60 is attached by stitching 62 and covers the whole of the base of the upper. In alternative embodiments, the midsole may be attached by other means, such as by ultrasonic welding. In alternative embodiments, the midsole is omitted, or only covers a portion of the base of the upper. Further the midsole may comprise one or more components and need not be a singular piece as shown in the Figure. The midsole or midsole components may additionally extend over the edges of the laminated composite to increase the contact area for attachment. The midsole 60 may further have a non-uniform thickness. In the present embodiment, the outsole 66 is attached by adhesive means 64 to the base of the midsole 60. The attachment may be performed by other means, such as by welding. The outsole 66 may be attached to the both the midsole 60 and the laminated composite 50, 52, or just to the laminated composite 50, 52. Additionally, the outsole 66 may comprise one or more components and need not be the singular piece as shown in the Figure. The outsole 66 or outsole components may additionally extend over the edges of the laminated composite 50, 52 to increase the contact area for attachment. The outsole 66 may also have a non-uniform thickness.

FIG. 4A shows the step of combining first shaped piece 50 and second shaped piece 52. In a further embodiment of the method of the present invention, the two shaped pieces 50, 52 are stacked.

FIG. 4B shows the lamination process, whereby the two shaped pieces 50, 52 then undergo a further laminating process. In the present embodiment, the laminating process takes place in a mold comprised of convex mold 58 and concave mold 56. Convex mold 58 and concave mold 56 are substantially adapted to complement each other. The shaped pieces 50, 52 are positioned between convex mold 58 and concave mold 56, the portions of the mold are pressed together and the shaped pieces 50, 52 are laminated. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as a lubricant) to one or more of the shaped pieces 50, 52, convex mold 58 and concave mold 56 to facilitate easier molding. It will be understood that the lamination need not take place in a mold. The lamination may further comprise the step of applying adhesive to one or more shaped pieces of the upper of the shoe to join one shaped piece to another of the one or more shaped pieces. The lamination may still further comprise the step of reshaping the laminated composite of first shaped piece 50 and second shaped piece 52, before, during or after the lamination.

FIG. 4C shows the use of an strip 70 to be placed around the rim of the opening of the laminated composite. The strip 70 may be attached by means of an adhesive 72. The strip forms a substantially circular rim and is joined to itself by ultrasonic welding. The means of attachment and joining are not intended to be limiting and other means, such as heat-treatment could be used. As is shown in the Figure, strip 70 forms a V-shaped fold around the edge of the laminated composite 50, 52 to seal the edges. In the present embodiment, the strip covers the entire rim of the composite but it will be understood that this is not required and the strip 70 may cover only a portion of the rim. The strip comprises a single layer 70 of material covered with an adhesive layer 72. However, the strip may comprise a plurality of layers, which may be joined by stitching, welding or some other joining means. In this embodiment, the strip is joined to itself by an ultrasonic weld 74; however alternative joining mechanism such as stitching may be suitable.

FIG. 4D shows the method of attaching a midsole 60 and an outsole 66 to the laminated composite 50, 52 (with strip 70). In the present embodiment, the midsole 60 is attached by stitching 62 and covers the whole of the base of the upper. In alternative embodiments, the midsole may be attached by other means, such as by ultrasonic welding. In alternative embodiments, the midsole is omitted, or only covers a portion of the base of the upper. Further the midsole may comprise one or more components and need not be a singular piece as shown in the Figure. The midsole or midsole components may additionally extend over the edges of the laminated composite to increase the contact area for attachment. The midsole 60 may further have a non-uniform thickness. In the present embodiment, the outsole 66 is attached by adhesive means 64 to the base of the midsole 60. The attachment may be performed by other means, such as by welding. The outsole 66 may be attached to the both the midsole 60 and the laminated composite 50, 52, or just to the laminated composite 50, 52. Additionally, the outsole 66 may comprise one or more components and need not be the singular piece as shown in the Figure. The outsole 66 or outsole components may additionally extend over the edges of the laminated composite 50, 52 to increase the contact area for attachment. The outsole 66 may also have a non-uniform thickness.

FIG. 5A shows the step of combining first shaped piece 50 and second shaped piece 52. In a further embodiment of the method of the present invention, the two shaped pieces 50, 52 are stacked.

FIG. 5B shows the lamination process, whereby the two shaped pieces 50, 52 then undergo a further laminating process. In this embodiment, the laminating process takes place in a mold comprised of a convex mold 58 and concave mold 56. Convex mold 58 and concave mold 56 are substantially adapted to complement each other. The shaped pieces 50, 52 are positioned between convex mold 58 and concave mold 56, the portions of the mold are pressed together and the shaped pieces 50, 52 are laminated. The molding may comprise the application of pressure and heat to expedite molding, and may comprise the application of fluid (such as a lubricant) to one or more of the shaped pieces 50, 52, convex mold 58 and concave mold 56 to facilitate easier molding. It will be understood that the lamination need not take place in a mold. The lamination may further comprise the step of applying adhesive to one or more shaped pieces of the upper of the shoe to join one shaped piece to another of the one or more shaped pieces. The lamination may still further comprise the step of reshaping the laminated composite of first shaped piece 50 and second shaped piece 52, before, during or after the lamination.

FIG. 5C shows the ‘hemming’ method of joining the edges of the laminated composite 50, 52. First shaped piece 50, when stacked, comprises a portion 80 which extends over the edge of second shaped piece 52. After lamination of the two pieces, the portion 80 of piece 50 remains un-laminated to piece 52. This portion is folded over the edge of second shaped piece 52 to form a ‘hem’ 82 which is then attached to the remainder of second shaped piece 52. The attachment may for example, be by stitching or welding, but other attachment means are possible. In the present embodiment, the hem 82 is positioned at the edge of the rim of the opening of the upper of the shoe, but alternative positions are possible. The hem 82 is also shown as a continuous hem around the entire opening, but the hem 82 may only extend over a portion of the rim. Furthermore, the hem 82 may be attached to one or more other shaped pieces. The hem 82 may alternatively be provided by an overlapping portion of the second shaped piece 52, or any other shaped piece if present.

FIG. 5D shows the method of attaching a midsole 60 and an outsole 66 to the laminated composite 50, 52 (with hem 82). In the present embodiment, the midsole 60 is attached by stitching 62 and covers the whole of the base of the upper. In alternative embodiments, the midsole may be attached by other means, such as by ultrasonic welding. In alternative embodiments, the midsole is omitted, or only covers a portion of the base of the upper. Further the midsole may comprise one or more components and need not be a singular piece as shown in the Figure. The midsole or midsole components may additionally extend over the edges of the laminated composite to increase the contact area for attachment. The midsole 60 may further have a non-uniform thickness. In the present embodiment, the outsole 66 is attached by adhesive means 64 to the base of the midsole 60. The attachment may be performed by other means, such as by welding. The outsole 66 may be attached to the both the midsole 60 and the laminated composite 50, 52, or just to the laminated composite 50, 52. Additionally, the outsole 66 may comprise one or more components and need not be the singular piece as shown in the Figure. The outsole 66 or outsole components may additionally extend over the edges of the laminated composite 50, 52 to increase the contact area for attachment. The outsole 66 may also have a non-uniform thickness.

FIG. 6A shows an embodiment of a screen printing method used to decorate the upper formed by the lamination of the first and second shaped pieces of the present invention. Laminated component 100, comprises foam layer 102 and fabric layer 106 joined by adhesive layer 104. The constituent layers may be joined by other means, for example by ultrasonic welding. Alternatively component 100 may comprise only a single layer. Furthermore there may be more than two material layers to be joined together. For example, there could be three material layers, each joined to at least one other by adhesive. Alternatively the joining means may differ from the join between the first and second layer and the join between the second and third layer. The layers 102, 106 are shown completely overlapping each other. This is not a requirement and layers 102, 106 may only partially overlap. If three or more layers are used, one or more of these may not overlap one or more other layers at all.

FIG. 6B shows a plan view and a perspective view of two screens of material which comprise a decorative pattern 100A and 100B. Both first screen 100A and second screen 100B are shown in the planar configuration and in a shaped configuration 110A, 110B. Portions of the decorative patterns 100A and 100B overlap as shown.

FIG. 6C shows an exploded view of a method of printing decorative pattern 100A onto laminated component 100. Decorative pattern 100A is positioned between printing medium 120 (which may comprise one or more of silicon, PU, resin, ink or another printing medium) and the laminated component 100 while the laminated component 100 is in a substantially planar configuration. The laminated component 100 may be subsequently shaped, for example by molding to produce the shaped component 110A. The advantage of this method is that the 2D printing technique can be applied to a substantially planar component, before it is shaped to form a component of the upper of a shoe. This may, for example reduce distortions in the design when it appears in the non-planar configuration, and may facilitate more geometrically straightforward and faster printing.

FIG. 6D shows the process of adding a second decorated pattern 100B to a laminated component 100 which has already had decorative pattern 100A printed thereon. Similarly to the method of FIG. 6C, the decorative pattern 100B is positioned between a printing medium 122 (which may comprise one or more of silicon, PU, resin, ink or another printing medium) and the laminated component 100 which has decorative pattern 100A already printed thereon while the laminated component 100 is in a substantially planar configuration. After printing, the laminated component 100 may be subsequently shaped, for example by molding to produce the shaped component 110A, 110B. Again, the advantage of this method is that the 2D printing technique can be applied to a substantially planar component, before it is shaped to form a component of the upper of a shoe. This may reduce the complexity of the method for printing multiple components of a decorative pattern onto a portion of the upper of a shoe as a decorative pattern may be ‘built up’ by multiple depositions of printer medium. This may also reduce distortions in the design when it appears in the non-planar configuration, and may further facilitate more geometrically straightforward and faster printing. Once printed and shaped, laminated component 110A, 110B may comprise a component or a shaped piece of the for forming the upper of a shoe as described in FIGS. 1-5.

The embodiments described herein and shown in the Figures are intended only to be exemplary, and are not limiting upon the scope of the disclosure. The skilled person will recognise that various alternative configurations not specifically described herein will still fall within the scope of the present invention. 

1. A method of forming an upper of a shoe, the method comprising the steps of: forming a first shaped piece of the shoe upper; forming a second shaped piece of the shoe upper; laminating the first shaped piece of the shoe upper to the second shaped piece of the shoe upper.
 2. The method of claim 1, wherein the laminating of the first shaped piece and second shaped piece occurs during molding.
 3. The method of claim 1, wherein the forming of at least one of the first shaped piece and the second shaped piece comprises one or more steps of molding.
 4. The method of claim 1, wherein the forming of at least one of the first shaped piece and the second shaped piece comprises one or more steps of laminating.
 5. The method of claim 1, wherein the forming of at least one of the first shaped piece and the second shaped piece comprises a step of trimming from a larger piece.
 6. The method of claim 1, wherein at least one of the first shaped piece and the second shaped piece is formed by joining two or more components to form the first shaped piece or the second shaped piece.
 7. The method of claim 6, wherein at least two of the components are joined together by one or more of: stitching; adhesive means; ultrasonic welding; or heat treatment.
 8. The method of claim 1, wherein the forming of at least one of the first shaped piece and the second shaped piece comprises the step of laminating two or more components.
 9. The method of claim 8, wherein the laminating of the two or more components occurs during one or more molding steps.
 10. The method of claim 6, wherein at least one of the components comprises a previously shaped component.
 11. The method of claim 10, wherein the previously shaped component is shaped by molding.
 12. The method of claim 6, wherein at least one of the components comprises a laminated component.
 13. The method of claim 6, wherein at least one of the components comprises one or more of fabric and foam.
 14. The method of claim 6, wherein at least one of the components comprises a portion at least partially adapted to overlay one or more other of the components.
 15. The method of claim 6, wherein at least one of the components comprises a cushioning component.
 16. The method of claim 15, wherein at least one of the components comprises a portion at least partially adapted to overlay one or more other of the components; and wherein the one or more cushioning components are positioned between overlaying portions.
 17. The method of claim 14, wherein at least one of the overlaying components further comprises a portion which does not overlay at least one other component.
 18. The method of claim 17, further comprising the step of hemming the portion which does not overlay the other component.
 19. The method of claim 1, wherein at least a portion of one of the first shaped piece and a portion of the second shaped piece is at least partially adapted to overlay a portion of the other shaped piece.
 20. The method of claim 19, wherein at least one of the first shaped piece and second shaped piece further comprises a portion which does not overlay the other piece.
 21. The method of claim 20, further comprising the step of hemming the portion of one of the first shaped piece and the second shaped piece which does not overlay the other shaped piece.
 22. The method of claim 1, further comprising the step of joining the first shaped piece to the second shape piece.
 23. The method of claim 22, wherein the joining of the first shaped piece to the second shaped piece occurs prior to the laminating.
 24. The method of claim 22, wherein the joining is performed by one or more of: stitching; adhesive means; ultrasonic welding; or heat treatment.
 25. The method of claim 1, further comprising the step of inverting the configuration of the pieces such that an outermost piece of the first shaped piece and second shaped piece becomes an innermost piece of the first shaped piece and second shaped piece.
 26. The method of claim 1, wherein at least a portion of the first shaped piece and at least a portion of the second shaped piece collectively form an aperture having a rim.
 27. The method of claim 26, further comprising the step of adding a strip to at least partially cover the rim of the aperture.
 28. The method of claim 27, wherein the strip is added by using one or more of: stitching; adhesive means; ultrasonic welding; or heat treatment.
 29. The method of claim 1, further comprising the step of attaching one or more sole components to the shoe upper.
 30. A method of making a shoe comprising the method of claim
 1. 31. An upper for a shoe, the upper comprising: a first, shaped piece; a second, shaped piece; wherein at least a portion of the first shaped piece and the second shaped piece are laminated together.
 32. The upper of claim 31, wherein at least one of the first and second shaped pieces is a molded piece.
 33. The upper of claim 31, wherein at least one of the first shaped piece and the second shaped piece is a laminated piece.
 34. The upper of claim 31, wherein at least one of the first and second shaped pieces comprises a plurality of components.
 35. The upper of claim 34, wherein at least two of the plurality of components are joined together by one or more of: stitching; adhesive means; ultrasonic welding; or heat treatment.
 36. The upper of claim 34, wherein at least one of the first shaped piece and the second shaped piece comprises a plurality of laminated components which collectively comprise the first shaped piece or the second shaped piece.
 37. The upper of claim 34, wherein at least one of the components comprises a previously shaped component.
 38. The upper of claim 37, wherein the previously shaped component is shaped by molding.
 39. The upper of claim 34, wherein at least one of the components comprises a laminated component.
 40. The upper of claim 34, wherein at least one of the components comprises one or more of fabric and foam.
 41. The upper of claim 34, wherein at least one of the components comprises a portion at least partially adapted to overlay one or more of the other components.
 42. The upper of claim 34, wherein at least one of the components is a cushioning component.
 43. The upper of claim 42, wherein at least one of the components comprises a portion at least partially adapted to overlay one or more of the other components; and wherein the one or more cushioning components are positioned between one or more of the overlaying portions of two or more other components.
 44. The upper of claim 42, wherein at least one of the overlaying components further comprises a portion which does not overlay the other component.
 45. The upper of claim 44, further comprising a hemmed portion which does not overlay the other component.
 46. The upper of claim 31, wherein at least a portion of one of the first shaped piece and second shaped piece is at least partially adapted to overlay the other of the first shaped piece and the second shaped piece.
 47. The upper of claim 46, wherein at least one of the first shaped piece and second shaped piece further comprises a portion which does not overlay the other piece.
 48. The upper of claim 47, further comprising a hemmed portion of one of the first shaped piece and the second shaped piece which does not overlay the other shaped piece.
 49. The upper of claim 31, wherein the first shaped piece and the second shape piece are joined.
 50. The upper of claim 49, wherein the join comprises one or more of: stitching; adhesive means; ultrasonic welding; or heat treatment.
 51. The upper of claim 31, wherein at least a portion of the first shaped piece and at least a portion of the second shaped piece collectively form an aperture with a rim.
 52. The upper of claim 31, further comprising a strip to at least partially cover the rim of the aperture.
 53. The upper of claim 52, wherein the strip is attached to the upper by one or more of: stitching; adhesive means; ultrasonic welding; or heat treatment.
 54. The upper of claim 31, further comprising one or more sole components.
 55. A shoe comprising an upper of claim
 31. 56. A method of forming a decorative pattern on a portion of an upper of a shoe, the method comprising: printing a decorative pattern on at least a portion of a shoe upper, the portion of the shoe upper having a substantially planar configuration; and shaping the portion of the shoe upper to form a predetermined shape.
 57. The method of claim 56, wherein the portion of the shoe upper comprises a laminated portion.
 58. The method of claim 56, wherein the shaping of the portion of the shoe upper to form a predetermined shape comprises molding.
 59. The method of claim 56, wherein the portion of the shoe upper comprises at least one of fabric, foam, plastic or leather.
 60. The method of claim 56, wherein the step of printing comprises screen printing.
 61. The method of claim 56, wherein the step of printing comprises printing on a plurality of substantially planar portions of the shoe upper.
 62. The method of claim 61, wherein the steps of printing onto one of the plurality of substantially planar portions occurs separately from the step of printing onto any other of the plurality of substantially planar portions.
 63. The method of claim 61, wherein the steps of printing onto one of the plurality of substantially planar portions occurs sequentially.
 64. The method of claim 56, further comprising the steps of: forming a first shaped piece of the shoe upper; forming a second shaped piece of the shoe upper; laminating the first shaped piece of the shoe upper to the second shaped piece of the shoe upper.
 65. A decorated portion of an upper for a shoe comprising: one or more layers of substantially planar material; and a decorative image; wherein the decorative image is printed on at least part of a surface of a portion of the shoe upper whilst the portion of the shoe upper is in a substantially planar configuration, and wherein the portion of the shoe upper is subsequently shaped into a predetermined shape.
 66. The decorated portion of claim 65, wherein the portion is at least partially a laminated portion.
 67. The decorated portion of claim 65, wherein the portion of the shoe upper comprises at least one of fabric, foam, plastic or leather.
 68. The decorated portion of claim 65, wherein the printed decorative image comprises at least one screen printed decorative image.
 69. The decorated portion of claim 65, further comprising: a first, shaped piece; a second, shaped piece; wherein at least a portion of the first shaped piece and the second shaped piece are laminated together. 